In the aviation, space, and defense industries, quality and reliability are non-negotiable. Advanced Product Quality Planning (APQP), a proactive project management approach, has been adopted across these sectors to identify and mitigate issues before they disrupt the production process. Defined in the International Aerospace Quality Group’s (IAQG) 9145 standard, APQP is revolutionizing how we manage and secure product quality, shifting the industry from reactive measures to structured, risk-based planning that prioritizes long-term stability.

From Automotive Origins to Aerospace Excellence

APQP’s roots trace back to the 1980s U.S. automotive industry, where fierce competition from Japanese manufacturers pushed companies like Ford, GM, and Chrysler to improve quality and consistency. They developed APQP to unify quality standards and empower suppliers to compete effectively by building robust, durable, and responsive products. The approach proved successful in automotive, leading to its adoption in other sectors like medical and government. Today, IAQG incorporates APQP through the 9145 standard, tailoring it to address the complexities of the aviation, space and defense industries.

The Core Tenets and Benefits of APQP

At its foundation, APQP fosters cross-functional collaboration, early identification of risks, and proactive quality planning. Its structured approach emphasizes engaging leadership, forming multidisciplinary teams, and closely managing projects. APQP offers numerous benefits for aerospace companies:

• Early Defect Identification: APQP’s structure allows for early identification of potential quality issues, minimizing defects that could surface later in production.
• Cross-Functional Collaboration: By breaking down organizational silos, APQP fosters open communication across functions, enhancing teamwork and aligning goals.
• Reduced Nonconformances: Proactively identifying and managing risks helps organizations avoid internal nonconformances and customer quality issues.
• Improved Supplier Performance: With clear guidelines for communication, requirements and quality expectations, APQP improves supplier performance and supports on-time delivery.
• Increased Customer Satisfaction: Meeting customer expectations through a structured quality framework enhances overall satisfaction and builds trust and reliability.

These APQP elements have enabled aerospace manufacturers to proactively manage quality, ensure compliance, and improve overall performance.

APQP’s Phased Approach to Quality

Utilizing a five-phased approach, APQP operates methodically, addressing risks at each stage of product development:

1. Planning: Collect requirements, define project scope, and set objectives aligned with customer needs.
2. Product Design and Development: Perform a Design Risk Analysis, such as a Design Failure Mode and Effects Analysis (DFMEA), to assess design risks and integrate preventative measures.
3. Process Design and Development: Incorporate Process Failure Mode and Effects Analysis (PFMEA) and control plans to ensure stable production processes.
4. Product and Process Validation: Perform validation activities, such as first article inspections, to confirm that processes meet quality standards.
5. Ongoing Production and Continuous Improvement: Apply lessons learned and best practices to reinforce quality and continuously improve processes.

These phases build a roadmap for achieving stability, repeatability, and compliance in production, helping organizations reduce errors and minimize costly rework.

The Role of PPAP in Ensuring Product Consistency

The Production Part Approval Process (PPAP), an integral component within APQP, is a structured method for confirming that production processes consistently meet requirements. PPAP involves collecting and reviewing core elements, including DFMEA, PFMEA, and control plans, to establish a quality baseline. It serves as critical evidence that production processes can reliably yield compliant parts and help manage product changes over time.

Updates and Clarifications in the Forthcoming 9145 Revision

The IAQG is currently revising the 9145 standard based on industry feedback to enhance clarity and usability. Key updates include distinguishing mandatory deliverables from optional elements and improving change management guidance. This revision aims to simplify and streamline quality planning, making it easier for organizations to adopt and implement APQP effectively.

Ensuring Aerospace Quality Through Industry Resources and Mentorship

To support APQP adoption, the IAQG’s Supply Chain Management Handbook (SCMH) offers a wealth of resources under section 7.3 APQP. These materials include webinars, guidance documentation, templates, and checklists to aid teams in implementing APQP principles.

Adopting APQP and the structured principles outlined in the 9145 standard allows the aviation, space, and defense industries to move toward a future where quality planning is proactive, collaborative, and deeply integrated. This shift represents a transformation in how our industry anticipates and addresses quality challenges, ultimately building resilience, trust, and excellence.